HPCF Series — Installation & Startup – South-Tek Systems

Applies to: HPCF Series — 1, 2, 4, and 6 K-cylinder/day configurations

Does NOT apply to: HPCF-SFI — see HPCF-SFI Installation & Startup

This article covers receiving and unpacking, system installation, and the initial and normal startup procedures for the HPCF Series nitrogen generator. Work through each section in order — do not attempt startup until installation is complete and verified.

⚠ Commissioning Required: Contact South-Tek Systems to schedule a remote or in-person commissioning before the first startup. The system should not be started without commissioning support. Call (910) 415-1880 or submit a ticket at southteksystems911.zendesk.com.

Receiving

The HPCF nitrogen generator and all components are securely packed to minimize the risk of shipping damage. Upon delivery, perform the following steps before signing the bill of lading:

Visually inspect all packaging and the crate exterior for signs of damage before unloading.
If visible shipping damage exists, note it on the bill of lading before signing. Do not refuse delivery — accept the shipment and immediately notify the carrier.
After unloading, verify all components against the packing list included with the shipment.
If any discrepancy is found — missing items, damaged components, or packing list mismatch — contact South-Tek Systems at (910) 415-1880 and have the model number and serial number ready.
Retain all packaging material. It may be required if the unit needs to be returned for service.

ℹ Note: South-Tek Systems is not responsible for damage incurred during transit. Freight damage claims must be filed with the carrier. Do not discard packaging until the inspection is complete.

Unpacking and Moving

The HPCF is bolted to the bottom of a wooden shipping crate and shipped upright. A forklift is required for unloading and positioning.

Open the wooden crate from the side stamped "OPEN THIS SIDE."
Unbolt the unit from the bottom of the crate.
Insert forklift forks through the open slots on the bottom skid of the generator.
Slowly back the generator out of the crate and move it carefully to its final installation location.
Once positioned, follow all applicable local and site codes for anchoring and equipment securing requirements.

⚠ Rigging Warning: Use only lifting and strapping equipment rated for the weight of the system. Attach rigging devices carefully and avoid heavy impacts or jolting motions — these can damage internal components and media. Lift slowly and steadily at all times.

Storage (If Not Installing Immediately)

If the unit will not be installed right away, store it properly to prevent damage to internal components:

Store indoors in a dry, climate-controlled environment.
Place desiccant packets inside the electrical cabinet to protect electronics from moisture.
Do not store near moving objects, heavy equipment, or anything that could fall and impact the unit.
If a unit equipped with an optional O2 analyzer is stored for more than one month, the oxygen fuel cell/analyzer must be removed, the port taped off, and the cell stored separately in a controlled environment.

System Installation

Complete the following steps in order. Refer to the General Arrangement Drawing included in the documentation package throughout this process — it contains the site-specific layout and connection details for your unit.

Position the nitrogen generator in the installation area as described in the Site & Utility Requirements article. Lift carefully to avoid damaging components.
Review the General Arrangement Drawing. It will show the full package layout — which may include an air compressor, refrigerant dryer, air cooler, air receiver tank, air filtration train, and nitrogen generator — and the required interconnecting plumbing between all components.
Install all other equipment included in the package (air compressor, refrigerant dryer, etc.) per the original equipment manufacturer's instructions.
Complete all interconnecting plumbing between components as shown in the General Arrangement Drawing. Interconnecting plumbing is not supplied as standard — final pipe sizing is to be determined by the local piping contractor.
If tank accessories (safety relief valves, gauges, isolation valves) are included with the package, install them per local codes. Refer to the Tank Fittings Package Drawing included with the unit.
Have a qualified electrician verify available power and complete all electrical connections to the generator and all other package equipment. Connect to an approved electrical box at the correct voltage and frequency as labeled on the unit nameplate. A certified electrician must review all electrical connections before startup.
With the system pressurized, check all piping, fittings, and hose connections for leaks. Use an appropriate leak detection solution. Shut off the air supply valve and fully depressurize the system before attempting to repair any leaks.

🛑 Material Compatibility: Only use piping materials, fittings, and hoses rated for the working pressure present at each point in the system. Never use materials that are not compatible with compressed air or nitrogen service at system operating pressures.

Initial Startup

Follow this procedure the first time the unit is started. For all subsequent startups, use the Normal Startup procedure below. Notify all personnel in the area before beginning startup.

ℹ First Start / Post-Shutdown Purge: When the generator is started for the first time, or after any prolonged shutdown period, oxygen and nitrogen in the lines may have equalized. Allow the system to run and purge fully before using product nitrogen for cylinder filling. Monitor purity readings and do not open the product valve to cylinders until design purity is confirmed.

Verify that the power connection matches the voltage and frequency labeled on the unit nameplate (110V or 220V / 1Ph / 50–60Hz). Confirm the touchscreen on the generator shows "Stopped" mode — the Start/Stop button in the upper left corner of the Home screen should be illuminated red.
Start the air compressor per the compressor manufacturer's instructions. Wait for the air receiver to fully pressurize to the compressor's design pressure, then open the air supply isolation valve to the generator.
Open the nitrogen supply valve out to the nitrogen storage tank, and open the gas sample valve from the tank to the generator. Leave the nitrogen out-to-process valve closed at this stage.
On the generator touchscreen, toggle both the Start/Stop button and the Booster Start button to the green (on) position. The generator will begin cycling through its process valves and pressurizing the left PSA bed. The booster will start filling once the nitrogen storage tank reaches sufficient pressure.
Observe the pressure gauges on both PSA pressure vessels for a minimum of 10 minutes and confirm the following:
- Beds cycle (switch) every 50–90 seconds.
- The pressurizing bed reaches within 3–5 PSIG of the incoming air supply pressure. Verify and readjust incoming air pressure to the design specification if needed.
- While one bed pressurizes, the other exhausts down to 0–10 PSIG.
Nitrogen will begin flowing to the nitrogen storage tank. Monitor the storage tank pressure as it builds.
When storage tank pressure reaches the cut-out pressure, the system will automatically enter "Standby" mode (indicated on the Home screen) and nitrogen production will pause.
Once the system is in Standby, open the nitrogen out-to-process valve. Storage tank pressure will begin to drop. When pressure falls to the cut-in pressure, the generator will automatically restart and resume filling the storage tank. This confirms automatic cut-in/cut-out operation is functioning correctly.

⚠ Leak Check During Startup: Check all pipe fittings and valve connections for leaks during the startup sequence. If a leak is found, shut off the air supply valve and fully depressurize the system before attempting any repairs.

Normal Startup

Use this procedure for all routine startups after the initial startup has been completed. Notify personnel in the area before beginning.

Open the air supply isolation valve.
On the generator touchscreen Home screen, toggle the Start/Stop button to Start. The button should illuminate green to confirm the system has started.
Toggle the Booster Start button. The booster will begin filling once nitrogen storage pressure reaches the required level.
Open any shutoff valves in the product nitrogen line to the user's piping system or cylinder manifold. Allow system purity to rise to design specification before connecting cylinders for filling.

ℹ System Opened to Atmosphere: If the generator or any part of the system has been opened to atmosphere (e.g., after maintenance), the system must be fully purged of residual air before product nitrogen is used for cylinder filling. Monitor purity on the touchscreen and confirm design purity is reached before opening to cylinders.

Shutdown

Normal Shutdown

Close the nitrogen out-to-process valve on the output of the nitrogen storage tank.
On the generator touchscreen Home screen, toggle the Start/Stop button to Stop.

Emergency Shutdown

In an emergency, turn off the main power switch on the generator. This immediately stops all generator functions. Nitrogen supply to process can be shut off manually by closing the nitrogen out-to-process valve on the output of the nitrogen storage tank.

🛑 System Remains Pressurized After Shutdown: The generator and associated piping will remain under pressure after shutdown. Before performing any maintenance, opening any piping connections, or removing any components, always fully depressurize the system. Failure to depressurize before working on the system may result in serious injury.

Contact South-Tek Systems

Phone: (910) 415-1880

Email / Ticket: support@southteksystems911.zendesk.com